ATV or Youth Sportsman Big Boss 6x6 800 EFI Owner's manual

Owner's Manual

for Maintenance and Safety

PMS 419

Read this manual carefully. It contains important safety information.

This is an adult vehicle only.

Operation is prohibited for those under 16 years of age.

Sportsman

Big Boss 6X6

WARNING

Read, understand, and follow all of the instructions and safety precautions in

this manual and on all product labels.

Failure to follow the safety precautions could result in serious injury or death.

WARNING

The engine exhaust from this product contains chemicals known to the State

of California to cause cancer, birth defects or other reproductive harm.

1

WELCOME

Thank you for purchasing a POLARIS vehicle, and welcome to our

world-wide family of POLARIS enthusiasts. Be sure to visit us online at

www.polaris.com for the latest news, new product introductions,

upcoming events, career opportunities and more.

Here at POLARIS we proudly produce an exciting line of utility and

recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• Low emission vehicles (LEVs)

• RANGER® utility vehicles

• RZR® sport vehicles

• VICTORY® motorcycles

• GEM® vehicles

We believe POLARIS sets a standard of excellence for all utility and

recreational vehicles manufactured in the world today. Many years of

experience have gone into the engineering, design, and development of

your POLARIS vehicle.

For safe and enjoyable operation of your vehicle, be sure to follow the

instructions and recommendations in this owner’s manual. Your manual

contains instructions for minor maintenance, but information about

major repairs is outlined in the POLARIS Service Manual and should be

performed only by a factory certified Master Service Dealer® (MSD)

technician.

Your POLARIS dealer knows your vehicle best and is interested in your

total satisfaction. Be sure to return to your dealership for all of your

service needs during, and after, the warranty period.

2

POLARIS®, SPORTSMAN® and BIG BOSS® are registered trademarks of POLARIS

Industries Inc.

is based on the latest product information at the time of publication. Due to constant

improvements in the design and quality of production components, some minor discrep-

ancies may result between the actual vehicle and the information presented in this publi-

cation. Depictions and/or procedures in this publication are intended for reference use

only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse

of the depictions and/or procedures contained within, whether whole or in part, is

expressly prohibited.

The original instructions for this vehicle are in English. Other languages are provided as

translations of the original instructions.

Printed in U.S.A.

2014 SPORTSMAN BIG BOSS 6X6 800 EFI Owner’s Manual

P/N 9924249

3

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Features and Controls. . . . . . . . . . . . . . . . . . . 26

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Winch Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Emission Control Systems . . . . . . . . . . . . . . . 78

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 130

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 134

POLARIS Products. . . . . . . . . . . . . . . . . . . . . 136

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 144

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

4

INTRODUCTION

The following signal words and symbols appear throughout this manual

and on your vehicle. Your safety is involved when these words and

symbols are used. Become familiar with their meanings before reading

the manual.

The safety alert symbol indicates a potential personal injury hazard.

DANGER

A DANGER indicates a hazardous situation that, if not avoided, will result in

death or serious injury.

WARNING

A WARNING indicates a hazardous situation that, if not avoided, could result in

death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation that, if not avoided, could result in

minor or moderate injury.

NOTICE

A NOTICE indicates a situation that could result in property damage.

The Prohibition Safety Sign indicates an action NOT to take in order

to avoid a hazard.

The Mandatory Action Sign indicates an action that NEEDS to be

taken to avoid a hazard.

5

INTRODUCTION

Failure to heed the warnings and safety precautions contained in this manual

can result in severe injury or death. This POLARIS vehicle is not a toy and can

be hazardous to operate. This vehicle handles differently than other vehicles,

such as motorcycles and cars. A collision or rollover can occur quickly, even

during routine maneuvers like turning, or driving on hills or over obstacles, if you

fail to take proper precautions.

• Read this owner’s manual. Understand all safety warnings, precautions and

operating procedures before operating this vehicle. Keep this manual with the

vehicle.

• Never operate this vehicle without proper instruction. Take a training course.

• This vehicle is an ADULT VEHICLE ONLY. Operation is prohibited for anyone

under 16 years of age.

• Never permit a guest to operate this vehicle unless the guest has read this

manual and all product labels and has completed a certified safety training

course.

European Vibration and Noise

The driver-perceived noise and hand/arm and whole body vibration

levels of this machinery is measured per prEN 15997.

The operating conditions of the machinery during testing:

The vehicles were in like-new condition. The environment was

controlled as indicated by the test procedure(s).

The uncertainty of vibration exposure measurement is dependent on

many factors, including:

• Instrument and calibration uncertainty

• Variations in the machine such as wear of components

• Variation of machine operators such as experience or physique

• Ability of the worker to reproduce typical work during measurements

• Environmental factors such as ambient noise or temperature

WARNING

6

INTRODUCTION

Vehicle Identification Numbers

Record your vehicle's identification numbers and key number in the

spaces provided. Remove the spare key and store it in a safe place. An

ignition key can be duplicated only by ordering a POLARIS key blank

(using your key number) and mating it with one of your existing keys.

The ignition switch must be replaced if all keys are lost.

Vehicle Model Number: ___________________________________________________

Frame VIN: ____________________________________________________________

Engine Serial Number: ___________________________________________________

Key Number: ___________________________________________________________

####

Engine Serial Number

Key Number

VIN

(front or rear frame)

7

SAFETY

Safety Training

ATV safety training is a top priority for POLARIS. POLARIS strongly

encourages you and any family members who will be riding the ATV to

take a training course.

If you purchased a new POLARIS ATV in the United States, your dealer

provided information about the authorized ATV RiderCourse

sm

that is

available to you and your eligible family members. This training is

included in the purchase price of your ATV. You were also provided

with printed materials that explain safe operating procedures. You

should review this information on a regular basis.

If you purchased a used POLARIS ATV in the United States, you can

enroll in the ATV RiderCourse

sm

for a fee. Call ATV Enrollment

Express at (800) 887-2887 or visit www.atvsafety.org.

If you purchased a POLARIS ATV outside the United States, please

contact your dealer or local law enforcement agencies for information

about safety training.

This POLARIS vehicle is an off-road vehicle. Familiarize yourself with

all laws and regulations concerning the operation of this vehicle in your

area.

We strongly advise you to strictly follow the recommended maintenance

program outlined in your owner's manual. This preventive maintenance

program is designed to ensure that all critical components on your

vehicle are thoroughly inspected at specific intervals.

FOR MORE INFORMATION ABOUT ATV SAFETY in the United

States, call the Consumer Product Safety Commission at 1-800-

638-2772, or visit www.cpsc.gov, visit www.atvsafety.org, or call

POLARIS at 1-800-342-3764.

8

SAFETY

Safe Riding Gear

Always wear appropriate clothing when riding this vehicle. Wear

protective clothing for comfort and to reduce the chance of injury.

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a

POLARIS vehicle, always wear a helmet that meets or exceeds

established safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of

Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania

bear the ECE 22.05 label. The ECE mark consists

of a circle surrounding the letter E, followed by the

distinguishing number of the country which has

granted approval. The approval number and serial

number will also be displayed on the label.

Helmet

Eye Protection

Gloves

Boots

Long Pants

Long

Sleeves

E

4

051039

0006.31

9

SAFETY

Safe Riding Gear

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection.

Whenever riding a POLARIS vehicle, always wear shatterproof goggles

or use a shatterproof helmet face shield. POLARIS recommends

wearing approved Personal Protective Equipment (PPE) bearing

markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye

wear is kept clean.

Gloves

Off-road style gloves with knuckle pads are the best for comfort and

protection.

Boots

The best footwear is a pair of sturdy over-the-calf boots with low heels.

Clothing

Always wear long sleeves and long pants to protect arms and legs.

Riding pants with kneepads and a jersey with shoulder pads provide the

best protection.

Equipment Modifications

We strongly recommend that consumers do not install on a POLARIS

vehicle any equipment that may increase the speed or power of the

vehicle, or make any other modifications to the vehicle for these

purposes.

The warranty on your POLARIS vehicle is terminated if any equipment

has been added to the vehicle, or if any modifications have been made to

the vehicle, that increase its speed or power.

The addition of certain accessories, including (but not limited to)

mowers, blades, tires, sprayers, or large racks, may change the handling

characteristics of the vehicle. Use only POLARIS-approved accessories,

and familiarize yourself with their function and effect on the vehicle.

10

SAFETY

Failure to operate the vehicle properly can result in a collision, loss of control,

accident or overturn, which may result in serious injury or death. Heed all safety

warnings outlined in this section of the owner’s manual. See the OPERATION

section of the owner’s manual for proper operating procedures.

Operating Without Instruction

Operating this vehicle without proper instruction

increases the risk of an accident. The operator

must understand how to operate the vehicle

properly in different situations and on different

types of terrain.

Beginning and inexperienced operators should

complete the recommended safety training before

operating this vehicle. See page 7.

Never permit a guest to operate the vehicle unless

the guest has read this manual and all product

labels and has completed a certified safety training

course.

Age Restrictions

This vehicle is an ADULT VEHICLE ONLY.

Operation is prohibited for anyone under 16 years

of age.

Even though a child may be within the

recommended age group for operating some

POLARIS vehicles, he/she may not have the skills,

abilities, or judgment needed to operate this

vehicle safely and could be susceptible to accident

or injury.

WARNING

11

SAFETY

Safety Warnings

Handling Gasoline

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel with the engine stopped, and outdoors or in a well ventilated

area.

• Do not smoke or allow open flames or sparks in or near the area where refu-

eling is performed or where gasoline is stored.

• Do not overfill the tank. Do not fill the tank neck.

• If gasoline spills on your skin or clothing, immediately wash it off with soap

and water and change clothing.

Exposure to Exhaust

Engine exhaust fumes are poisonous and can cause loss of consciousness or

death in a short time. Never start the engine or let it run in an enclosed area.

The engine exhaust from this product contains chemicals known to cause

cancer, birth defects or other reproductive harm. Operate this vehicle only

outdoors or in well-ventilated areas.

Failure to Inspect Before Operating

Failure to inspect and verify that the vehicle is in

safe operating condition before operating

increases the risk of an accident.

Always inspect the vehicle before each use to

make sure it's in safe operating condition.

Always follow all inspection and maintenance

procedures and schedules described in the

owner's manual.

12

SAFETY

Safety Warnings

Protective Apparel

Riding on this vehicle without wearing an

approved helmet and protective eyewear

increases the risk of a serious injuries in the

event of an accident.

Operator and passenger must always wear an

approved helmet that fits properly and eye

protection (goggles or face shield).

Using Alcohol or Drugs

Operating the vehicle after consuming

alcohol or drugs could adversely affect

operator judgment, reaction time,

balance and perception.

Never consume alcohol or drugs before

or while operating this vehicle.

Carrying a Passenger

Carrying a passenger greatly reduces the

operator's ability to balance and control the

vehicle, which may result in an accident or

overturn.

Never carry a passenger on this vehicle.

13

SAFETY

Safety Warnings

Operating on Pavement

Operating this vehicle on paved surfaces

(including sidewalks, paths, parking lots and

driveways) may adversely affect the

handling of the vehicle and could result in

loss of control and accident or overturn.

Avoid operating the vehicle on pavement.

The tires are designed for off-road use. If it's

unavoidable, travel slowly and avoid sudden

turns or stops.

Operating on Public Roads

Operating this vehicle on public streets,

roads or highways could result in a collision

with another vehicle.

Never operate the vehicle on any public

street, road or highway, including dirt and

gravel roads. In many states it's unlawful to

operate this type of vehicle on public

streets, roads and highways.

Operating at Excessive

Speeds

Operating the vehicle at excessive speeds

increases the operator's risk of losing

control.

Always operate at a speed that's

appropriate for the terrain, the visibility and

operating conditions, and your experience.

14

SAFETY

Safety Warnings

Physical Control of the Vehicle

Removing a hand from the handlebars or

feet from the footrests during operation can

reduce your ability to control the vehicle or

cause loss of balance and ejection from the

vehicle. If the operator's foot is not firmly

planted on the footrest, it could also contact

the rear wheels.

Never remove your hands from the

handlebars while operating, and always

keep both feet on the footrests.

Turning Improperly

Turning improperly could cause loss of

traction, loss of control, accident or overturn.

Always follow proper procedures for turning

as described in the owner's manual.

Never turn abruptly or at sharp angles. Never

turn at high speeds. Practice turning at slow

speeds before attempting to turn at faster

speeds.

Jumps and Stunts

Attempting wheelies, jumps and other

stunts increases the risk of an accident or

overturn.

Never attempt wheelies, jumps, or other

stunts. Avoid exhibition driving.

Improper Hill Climbing

Improper hill climbing could cause loss of

control or overturn. Always follow proper

procedures for climbing hills as described in

the owner's manual. See page 55. Always

move the 4X4 switch to ADC 4X4 (if

equipped) before ascending or descending a hill.

15

SAFETY

Safety Warnings

Descending Hills Improperly

Improperly descending a hill could cause loss

of control or overturn.

• Always follow proper procedures for travel-

ing down hills as described in the owner's

manual. NOTE: A special technique is

required when braking while traveling down-

hill. See page 57.

• Always descend a hill with the transmission

in forward gear. Do not descend a hill with

the transmission in neutral. Always move the

4X4 switch to ADC 4X4 (if equipped) before

ascending or descending a hill. See page 36.

• Always check the terrain carefully before descending a hill.

• Shift your weight rearward.

• Never travel down a hill at high speed.

• Avoid traveling down a hill at an angle, which would cause the vehicle to lean

sharply to one side. Travel straight down the hill when possible.

Crossing Hillsides

Driving on a sidehill is not recommended. Improper procedure could cause loss

of control or overturn. Avoid crossing the side of any hill unless absolutely

necessary.

If crossing a hillside is unavoidable, always follow proper procedures as

described in the owner's manual. See page 56.

Never attempt to turn the vehicle around on any hill until you've mastered the

turning technique (on level ground) as described in the owner's manual. See

page 58.

16

SAFETY

Safety Warnings

Stalling While Climbing a Hill

Stalling, rolling backwards or improperly

dismounting while climbing a hill could cause an

overturn.

• Always maintain a steady speed when climbing

a hill.

• Always move the 4X4 switch to ADC 4X4 (if

equipped) before ascending or descending a

hill. See page 36.

If all forward speed is lost:

• Keep body weight uphill.

• Apply the service brakes.

• Lock the parking brake when fully stopped.

• Dismount on uphill side, or to either side if the vehicle is pointed straight

uphill.

• Turn the vehicle around and remount, following the procedure described in

the owner's manual. See page 58.

If the vehicle begins rolling downhill:

• Keep body weight uphill.

• Never apply engine power.

• Never apply the rear brake while rolling backwards. Apply the service brake

gradually.

• When fully stopped, apply the rear brake as well, and then lock the parking

brake.

• Dismount on uphill side, or to either side if the vehicle is pointed straight

uphill.

• Turn the vehicle around and remount, following the procedure described in

the owner's manual. See page 58.

17

SAFETY

Safety Warnings

Operating on Steep Hills

Operating on excessively steep hills could cause

an overturn.

Never operate on hills too steep for the vehicle or

for your abilities. Never operate the vehicle on hills

steeper than 25 degrees.

Operating on Slippery Terrain

Failure to use extra caution when operating on

excessively rough, slippery or loose terrain could

cause loss of traction, loss of control, accident or

overturn.

Do not operate on excessively rough, slippery or

loose terrain. Always use extra caution on rough,

slippery or loose terrain.

Operating in Unfamiliar Terrain

Failure to use extra caution when operating on

unfamiliar terrain could result in an accident or

overturn.

Unfamiliar terrain may contain hidden rocks,

bumps, or holes that could cause loss of control or

overturn.

Travel slowly and use extra caution when operating

on unfamiliar terrain. Always be alert to changing

terrain conditions.

18

SAFETY

Safety Warnings

Improper Tire Maintenance

Operating this vehicle with improper

tires or with improper or uneven tire

pressure could cause loss of control or

accident.

Always use the size and type of tires

specified for your vehicle.

Always maintain proper tire pressure as

described in the owner's manual and

on safety labels.

Operating Over Obstacles

Improperly operating over obstacles could cause loss of control or overturn.

Before operating in a new area, check for obstacles. Avoid operating over large

obstacles such as rocks and fallen trees. If unavoidable, use extreme caution

and always follow proper operating procedures as outlined in this manual. See

page 60.

Skidding or Sliding

Skidding or sliding can cause loss of control or overturn (if tires regain traction

unexpectedly).

On slippery surfaces such as ice or loose gravel, travel slowly and use extra

caution to reduce the chance of skidding or sliding. Do not operate on

excessively slippery surfaces.

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